AX15 Trans kicks out of 2nd gear

sba328

Member
Joined
Apr 9, 2007
Location
Summerfield, NC
I've got a 93 Wrangler Sahara with AX15 5 speed trans, that kicks out of 2nd gear on deceleration. 161,000 miles

I bought a rebuild kit, pulled the trans, put new bearings, seals, synchro's, new "reverse gear & 1-2 synchronizer sleeve", reverse gear (small gear), all the inserts & insert springs, put it back together, and still have the problem.

Doesn't happen in any other gear. Acceleration no problem, but let off the gas it kicks out.

A mechanic friend says it has excess play in the stackup of gear components along the output shaft, but frankly I don't know what else to look for, nearly every 2nd gear component except the "first/reverse hub" was changed out.

Any ideas?
 
The mechanic is right! There are critical shims that must be evaluated and replace with thicker ones during a rebuild. Typically at 1-2 and 3-4 or 4-5 depending on your particular transmission. I have learned this the hard way too.
 
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